Toilet Tank Flush Valve with Magnetically Assisted Closure

ABSTRACT

A toilet tank flush valve ( 100 ) includes: a valve seat ( 120 ); a stopper ( 110 ) movable between an open position wherein the stopper ( 110 ) is displaced from the seat ( 120 ) and a closed position wherein the stopper ( 110 ) is in contact with the seat ( 120 ); and, a magnet arranged to urge the stopper ( 110 ) toward the closed position.

FIELD

The present inventive subject matter relates to the plumbing arts. One particular application is found in conjunction with a toilet tank flush valve, and the specification makes particular reference thereto. However, it is to be appreciated that aspects of the present inventive subject matter are also amenable to other like applications.

BACKGROUND

As is known in the art, a toilet tank flush valve is generally arranged at the bottom of a toilet tank and regulates the flow of water from the toilet tank into an associated toilet bowl. A typical flush value includes a stopper and a flush valve seat. When the flush valve is closed, the stopper fits snuggly in contact with the seat forming a seal therebetween and blocking the flow of water through the flush valve, i.e., from the tank into the bowl. To open the valve, the stopper is pulled away or otherwise removed from the seat allowing water to flow from the tank through the valve into the bowl.

The stopper often takes the form of a flapper hinged at one end about which the flapper can swing, e.g., between opened (i.e., away from the valve seat) and closed (i.e., toward the valve seat) positions. In other another application, the stopper takes the form of a flush ball or plug that is linearly translated between opened and closed positions. In either case, commonly, the stopper is made to be somewhat or slightly buoyant, e.g., by having an air pocket formed therein. After being opened (i.e., removed from the seat), the opening force applied to the stopper is generally released and the buoyancy of the stopper keeps it from shutting prematurely, thereby allowing a sufficient amount of water to flow through the flush valve. That is to say, while the stopper is displaced from the seat, water flows out of the tank through the valve into the bowl. As the water level in the tank lowers due to the water escaping through the flush valve, the stopper descends gradually (due to its buoyancy) until it comes to rest in contact with the seat again. Meanwhile, the tank is being refilled by a filling mechanism, albeit usually at a rate less than it is being emptied. Once the stopper is again positioned in contact with the seat, water pressure produced by the water that is refilling the tank holds the stopper in place thereby keeping the flush valve closed. With the flush valve being held closed by the water pressure produced by the water in the tank, the water level in the tank rises accordingly so long as the filling mechanism remains on. As is known in the art, the filling mechanism is automatically shut off when the water in the tank reaches a set level.

Generally, the stopper (or the portion thereof that makes contact with the seat) is made from a suitably deformable and/or resilient material such as rubber, vinyl or the like, so that when the stopper is in the closed position, a water tight seal is formed with the flush valve seat. However, deformities, imperfections, degradation, misalignments and/or other irregularities in either the stopper and/or the seat can result in a less than water tight seal being formed and/or maintained. Accordingly, the flush valve leaks water out of the tank and into the bowl.

A leaky flush valve is generally undesirable. For example, it wastes water. Also, the gradual leak generally causes the toilet to run intermittently as the automatic refill mechanism attempts to maintain the water level in the tank at the set height. Such intermittent running can be a significant annoyance.

Accordingly, a new and improved toilet tank flush valve is disclosed that overcomes the above-referenced problems and others.

SUMMARY

In accordance with one embodiment, a toilet tank flush valve is provided. The toilet tank flush valve includes: a valve seat; a stopper movable between an open position wherein the stopper is displaced from the seat and a closed position wherein the stopper is in contact with the seat; and, a magnet arranged to urge the stopper toward the closed position.

In accordance with another embodiment, a toilet includes the aforementioned flush valve arranged operatively between a toilet tank and a toilet bowl.

In accordance with another embodiment, a method of operating a toilet tank flush valve includes: applying a force to displace a stopper from a seat such that a fluid is allowed to flow through an associated valve; discontinuing the applied force; and, magnetically attracting the stopper toward the seat.

Numerous advantages and benefits of the inventive subject matter disclosed herein will become apparent to those of ordinary skill in the art upon reading and understanding the present specification.

BRIEF DESCRIPTION OF THE DRAWINGS

The inventive subject matter may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting. Further, it is to be appreciated that the drawings are not to scale.

FIG. 1 is a diagram illustrating a toilet having an exemplary flush valve that embodies aspects of the present inventive subject matter.

FIG. 2 is a diagram illustrating an exemplary flush valve that embodies aspects of present inventive subject matter.

DETAILED DESCRIPTION

For clarity and simplicity, the present specification shall refer to structural and/or functional elements, components and/or features that are commonly known in the art without further detailed explanation as to their configuration or operation except to the extent they have been modified or altered in accordance with and/or to accommodate the embodiment(s) presented herein.

With reference to FIG. 1, a toilet A includes a toilet tank 10 and an associated toilet bowl 12. A water supply line 14 is shown for supplying the tank 10 with water via a fill valve 16 which regulates the flow of water into the tank 10 from the supply line 14. A buoyant float 18 is connected to the fill valve 16 via an arm 20 or other suitable linkage.

In the usual manner, the float 18 floats on the water in the tank 10. Accordingly, when water is released from the tank 10 and/or the water level in the tank 10 is lowered, the float 18 descends thereby actuating the arm 20, which in turn opens the fill valve 16 so that the tank 10 is filled or otherwise supplied with water from the supply line 14. Conversely, as the tank 10 is refilling and/or the water level in the tank 10 rises, the float 18 ascends accordingly, thereby actuating the arm 20 in the opposite direction to close the fill valve 16. When the water level in the tank 10 reaches a set height or level (e.g., an upper limit), the fill valve 16 is completely closed thereby blocking the further supply of water into the tank 10 from the supply line 14.

In the illustrated embodiment, a flush valve 100 is arranged at the base or bottom of the tank 10 to regulate the flow of water from the tank 10 into the bowl 12. The flush valve 100 includes a stopper 110 and a valve seat 120. When the flush valve is closed (as shown in FIG. 1), the stopper 110 fits snuggly in contact with the seat 120 forming a seal therebetween and blocking the flow of water through the flush valve 100, i.e., from the tank 10 into the bowl 12. To open the valve 100, the stopper 110 is pulled away or otherwise removed from the seat 120 allowing water to flow from the tank 10 through the valve 100 into the bowl 12. For example, FIG. 2 shows an open flush valve 100.

As shown in FIG. 1, the stopper 110 takes the form of a flapper that is secured in the tank 10 via a hinge 112 arranged at one end of the flapper. Accordingly, the flapper is able swing or pivot about the hinge 112, e.g., between a closed position and an opened position. In other another suitable embodiment, the stopper 110 takes the form of a flush ball or plug that is linearly translated between opened and closed positions. Whether the stopper 110 takes the form of a pivoting flapper or a linearly movable plug or some other suitable configuration, when the stopper 110 is in the open position and/or the valve 100 is otherwise open (e.g., as shown in FIG. 2), the stopper 110 is displaced from the seat 120, thereby allowing water from the tank 10 to flow through the valve 100 and into the bowl 12. Conversely, when the stopper 110 is in the closed position and/or the valve 100 is closed (e.g., as shown in FIG. 1), the stopper 110 contacts the seat 120 and forms a water tight seal therewith blocking the flow of water from the tank 10 into the bowl 12.

Optionally, to help achieve a water tight seal when the flush valve 100 is closed, the stopper 110 (or at least the portion thereof that makes contact with the seat 120) is made from a suitably deformable and/or resilient material, e.g., such as vinyl, rubber or the like. The stopper 110 is also made to be suitably buoyant. For example, optionally, an air pocket is formed in the stopper 110 to achieve the appropriate buoyancy.

In the illustrated embodiment, a flush assembly is provided to selectively flush the toilet A. More specifically, the flush assembly operates to open an otherwise closed flush valve 100, e.g., by pulling or displacing the stopper 110 from the seat 120 and braking the seal therebetween. In the illustrated embodiment, the flush assembly includes a lever or handle 30 that is operatively connected to the stopper 110 via a suitable linkage. As shown, the linkage includes an arm 32 and a line 34 (e.g., a chain, a cord, a cable, etc.) that cooperate to operative join the handle to the stopper 110. The arm 32 is connected at one end to the handle 30 and at the other end to the line 34 which is in turn connected to the stopper 110. Accordingly, to flush the toilet A, the handle 30 is depressed so as to pivot about a fulcrum 36, thereby actuating the arm 32 so as to pull the line 34 and displace the stopper 110 from the seat 120. Alternately, other suitable flush assemblies are employed.

After the valve 100 is opened (i.e., after the stopper 110 has been displaced from the seat 120), the opening force applied to the stopper 110 is discontinued (i.e., the handle 30 is released). The buoyancy of the stopper 110 keeps it from shutting prematurely, thereby allowing a sufficient amount of water to flow through the flush valve 100. That is to say, while the stopper 110 is displaced from the seat 120, water flows out of the tank 10 through the valve 100 into the bowl 112. As the water level in the tank 10 lowers due to the water escaping through the flush valve 100, the stopper 110 descends gradually (due to its buoyancy) until it comes to rest in contact with the seat 120 again. Meanwhile, the tank 10 is being refilled by the filling mechanism, albeit at a rate less than it is being emptied. Once the stopper 110 is again positioned in contact with the seat 120, water pressure produced by the water that is refilling the tank 10 holds the stopper 110 in place thereby keeping the flush valve 100 closed. With the flush valve 100 being held closed by the water pressure produced by the water in the tank 10, the water level in the tank 10 rises accordingly so long as the filling mechanism remains on. Eventually, the filling mechanism is automatically shut off when the water in the tank 10 reaches a set height or level.

To provide an improved seal as compared to conventional flush valves and/or to guard against leaks, the flush valve 100 incorporates and/or is provided a magnetically assisted closure. In general, a magnetic force is employed to urge the stopper 110 toward the seat 120. Suitably, a magnet or magnetized material is attached to and/or incorporated in the stopper 110 and a magnetic material is attached to and/or incorporated in the seat 120. Alternately, a magnet or magnetized material is attached to and/or incorporated in the seat 120 and a magnetic material is attached to and/or incorporated in the stopper 110. In yet another embodiment, suitably, magnets or magnetized materials having opposite polarities facing one another are attached to and/or incorporated in both the stopper 110 and the seat 120.

For example, with reference to FIG. 2, the stopper 110 includes a main body 114 dimensioned to fit in an opening 122 of the seat 120. As shown, the seat 120 includes a collar 124 that defines the opening 122 and a flange 126 that is used to secure the seat 120 to the base or bottom of the tank 10. Suitably, the main body 114 of the stopper 110 contains an air pocket therein to provided the appropriate buoyancy to the stopper 110. The stopper 110 also includes a gasket or gasket portion 116 dimensioned and/or arranged to make contact with the collar 124 of the seat 120 when the valve 100 is closed. That is to say, suitably, the gasket portion 116 of the stopper 110 aligns with the collar 124 when the valve 100 is closed.

Suitably, the gasket portion 116 of the stopper 110 is made from vinyl, rubber or another likewise deformable and/or resilient material in which particles of magnetic materials (e.g., iron or other metal fillings) are embedded and/or dispersed. Alternately, a ring or washer made of magnetic material is embedded or covered in vinyl, rubber or another likewise deformable and/or resilient material to form the gasket 116. Optionally, the collar 124 is provided with the deformable and/or resilient surface rather than or in addition to the deformable and/or resilient surface being provided on the stopper 110. That is to say, the objective is to have an interface between the stopper 110 and seat 120 that conforms the contacting surfaces of the components to one another so as attain a water tight seal. Accordingly, a deformable and/or resilient surface that achieves the desired conformity may reside on the stopper 110, the seat 120 or both components where they interface with and/or contact one another.

In one suitable embodiment, the collar 124 is made from a magnet or magnetized material so as to attract the magnetic materials in the gasket 116 and urge the stopper 110 toward the seat 120. Accordingly, when the valve 100 is closed the deformable and/or resilient outer surface of the gasket 116 conforms nicely or closely to the surface of the collar 124 where contact is made, thereby achieving a water tight seal. Suitably, the collar 124 is made from a magnetized iron or other suitable magnetized material, e.g., optionally coated in plastic or some other suitable barrier to prevent rusting.

In an alternate embodiment, the magnetic material is placed in or on the seat 120 while the magnetized material is placed in or on the stopper 110. While this alternate embodiment is suitable, there may be some instances when there is an advantage to not “magnetizing” the stopper 10. For example, insomuch as one may want to periodically replace the stopper 110 due to wear or for other reasons, some cost savings can be realized by not having the stopper 110 be the magnetized component.

Optionally, the magnetically assisted closure is adapted to be retrofit in a toilet with an otherwise conventional flush valve. For example, to carry out the retrofit, the otherwise standard stopper is removed and replaced with a stopper such as the one described herein, e.g., made at least partially from magnetic or magnetized material. Depending on the type of replacement stopper installed, a ring or donut shaped magnet or similarly shaped magnetic or magnetized material is then installed (e.g., adhered or bonded) around the outer perimeter of the collar of the otherwise standard seat. The resulting magnetic attraction between the newly installed components accordingly urges the stopper toward the seat to achieve an improved water tight seal as compared to the previous seal which may have been permitting leaks.

Suitably, the magnetic force urging the stopper 110 toward the seat 120 is uniformly distributed to ensure a good closure or seal around the entire perimeter of the opening 122. For example, to achieve a uniform distribution of the magnetic force, the magnetic particles in the gasket 116 are uniformly distributed throughout the gasket 116 and the magnetized collar 124 is uniformly magnetized. Moreover, the amount of magnetic material and/or the degree of magnetization is appropriately selected to achieve a suitable magnetic force that can still be over come to displace the stopper 110 from the seat 120 by operation of the flush assembly and that will not prematurely pull the stopper 110 back into the closed position. With respect to the latter issue, it is to be appreciated that the magnetic force falls off with the square of the distance between stopper 110 and the seat 120. Accordingly, the force is weaker at the beginning of the flush cycle (i.e., with the stopper 110 at its greatest displacement from the seat 120). In other words, the magnetic closure has relatively less effect while the stopper 110 is relatively father from the seat 120. Therefore, the stopper 110 at the beginning of the flush cycle is not being closed significantly faster (if at all) than it would be without the magnetically assisted closure. Hence, a sufficient amount of water is still permitted to flow through the valve 100 to achieve an effective flush of the toilet A. Of course, as the stopper 110 approaches closer to the seat 120, the magnetic force increases. Advantageously, when the valve 100 eventually closes completely, the magnetic force is at its greatest and accordingly assists in providing the improved water tight seal.

It is to be appreciated that in connection with the particular exemplary embodiments presented herein certain structural and/or function features are described as being incorporated in defined elements and/or components. However, it is contemplated that these features may, to the same or similar benefit, also likewise be incorporated in other elements and/or components where appropriate. It is also to be appreciated that different aspects of the exemplary embodiments may be selectively employed as appropriate to achieve other alternate embodiments suited for desired applications, the other alternate embodiments thereby realizing the respective advantages of the aspects incorporated therein.

Additionally, it is to be appreciated that certain elements described herein as incorporated together may under suitable circumstances be stand-alone elements or otherwise divided. Similarly, a plurality of particular functions described as being carried out by one particular element may be carried out by a plurality of distinct elements acting independently to carry out individual functions, or certain individual functions may be split-up and carried out by a plurality of distinct elements acting in concert. Alternately, some elements or components otherwise described and/or shown herein as distinct from one another may be physically or functionally combined where appropriate.

In short, the present specification has been set forth with reference to preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the present specification. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 

1. A toilet tank flush valve comprising: a valve seat; a stopper movable between an open position wherein the stopper is displaced from the seat and a closed position wherein the stopper is in contact with the seat; and, a magnet arranged to urge the stopper toward the closed position.
 2. The flush valve of claim 1, wherein the magnet is included in the valve seat, and the stopper includes a magnetic material that is attracted to the magnet.
 3. The flush valve of claim 2, wherein the valve seat includes a magnetized collar that comprises the magnet, and at least a portion of the stopper is formed from a base material having particles of magnetic material embedded therein.
 4. The flush valve of claim 3, wherein the collar has a magnetized iron core coated with a water proof barrier.
 5. The flush valve of claim 3, wherein the particles of magnetic material are iron filings.
 6. The flush valve of claim 3, wherein the particles of magnetic material are evenly distributed throughout the base material.
 7. The flush valve of claim 3, wherein the base material is one of rubber or vinyl.
 8. The flush valve of claim 1, wherein the stopper has a degree of buoyancy.
 9. The flush valve of claim 1, wherein the stopper has an air pocket formed therein.
 10. A toilet including the flush valve of claim 1 arranged operatively between a toilet tank and a toilet bowl.
 11. The toilet of claim 10, further comprising: a filling mechanism that supplies water to the tank when a water level in the tank drops below a set point.
 12. The toilet of claim 10, further comprising: a flush assembly that operates to displace the stopper from the seat.
 13. A method of operating a toilet tank flush valve, said method comprising: (a) applying a force to displace a stopper from a seat such that a fluid is allowed to flow through an associated valve; (b) discontinuing the applied force; and, (c) magnetically attracting the stopper toward the seat.
 14. The method of claim 8, wherein the stopper is movable between an open position in which the stopper is displaced from the seat and a closed position in which the stopper is in contact with the seat.
 15. The method of claim 9, wherein the stopper is movable between the open and closed positions by pivoting the stopper about a hinge.
 16. The method of claim 9, wherein the stopper is movable between the open and closed positions by linearly translating the stopper.
 17. The method of claim 9, wherein application of the force is achieved by manual operation of a handle.
 18. The method of claim 12, wherein the handle is connected to the stopper through a mechanical linkage.
 19. The method of claim 12, wherein discontinuing the applied force is achieved by releasing the handle. 